OGX Petróleo e Gás ParticipaçõesS.A., Subsidiaries & AffiliatesMANAGEMENT PROCEDURE PG.OG.SMS.018Title:Mechanical Integrit...
OGX Petróleo e Gás ParticipaçõesS.A., Subsidiaries & AffiliatesMANAGEMENT PROCEDURE PG.OG.SMS.018Title:Mechanical Integrit...
OGX Petróleo e Gás ParticipaçõesS.A., Subsidiaries & AffiliatesMANAGEMENT PROCEDURE PG.OG.SMS.018Title:Mechanical Integrit...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 4 of 174.9 - HP - Hold...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 5 of 175 – Responsibil...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 6 of 17 Progress trac...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 7 of 17 key links bet...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 8 of 17where possible,...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 9 of 17• Effectiveness...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 10 of 17Annex 1 – Chec...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 11 of 17REFERENCE DOCU...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 12 of 17NOTE: REFER TO...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 13 of 17Annex 2 - Equi...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 14 of 17Annex 3 - Stru...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 15 of 17Annex 4 - SGSO...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 16 of 17Annex 5 - Diag...
Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 17 of 17Annex 6 - Func...
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Pg og sms 018 procedimento de integridade mecânica eng

  1. 1. OGX Petróleo e Gás ParticipaçõesS.A., Subsidiaries & AffiliatesMANAGEMENT PROCEDURE PG.OG.SMS.018Title:Mechanical IntegrityIssued on: 04/May/12 Version 01Prepared by:Alter AzevedoSSO EngineerRevised by:Hegel BernardesSSO ManagerApproved by:Reinaldo BelottiDevelop. and Production DirectorPage 1 of 17SUMMARYThe purpose of this procedure is to set up the conditions that will allow the performance ofinspections, tests, repairs and maintenance, taking into consideration the equipmentdeterioration mechanisms, trying to preserve their integrity and reliability.TABLE OF CONTENTS1 – Objective: 32 – Application and Scope: 33 – References: 34 – Definitions and Acronyms: 35 – Responsibilities: 46 – Assumptions: 47 – Records: 68 – Annexes: 6The content of this procedure must be disclosed to all employees.Requests for clarification should be sent to the Operational Health and Safety by e-mailaddressed to alter.azevedo@ogx.com.br
  2. 2. OGX Petróleo e Gás ParticipaçõesS.A., Subsidiaries & AffiliatesMANAGEMENT PROCEDURE PG.OG.SMS.018Title:Mechanical IntegrityIssued on: 04/May/12 Version 01Prepared by:Alter AzevedoSSO EngineerRevised by:Hegel BernardesSSO ManagerApproved by:Reinaldo BelottiDevelop. and Production DirectorPage 2 of 17REVISION/ISSUE CONTROLIssue Version Date TopicsType(I / E / A / N)Summary of changes2012 01 04/May/12 NA N Establishment of the procedureREVISION RECORD CODE – TYPE OF CHANGEAcronym DescriptionI Inclusion: New information was added.E Exclusion: Information excluded from prior version.A Change or adjustment to information existing in the previous version.N New: Shows procedure establishment date, corresponding to document 1st version.Additional Information: (Field for comments or guidance for next revision or specific issues related to procedure subjectmatter).
  3. 3. OGX Petróleo e Gás ParticipaçõesS.A., Subsidiaries & AffiliatesMANAGEMENT PROCEDURE PG.OG.SMS.018Title:Mechanical IntegrityIssued on: 04/May/12 Version 01Prepared by:Alter AzevedoSSO EngineerRevised by:Hegel BernardesSSO ManagerApproved by:Reinaldo BelottiDevelop. and Production DirectorPage 3 of 171 – Objective:The objective of this procedure is to establish, in a planned and systematic manner, therequirements to be applied by Operational Safety Management System (SGSO) to performinspections, tests, repairs and maintenance, taking into account the mechanisms of equipmentdeterioration, seeking to preserve its integrity and reliability.2 – Application and Scope:This procedure applies to onshore and offshore facilities connected to OGX and OGXcontractors oil and natural gas drilling and production operations.This procedure is to be implemented based on the Risk Analysis study, Critical Systems, and onequipment construction design standards. Good operating practices are those described in themanufacturers manuals and in the operational procedures issued by OGX.3 – References: Risk Assessment Study Preparation Procedure – PG.OG.SMS.002 Critical Equipment Management Procedure – PG.OG.SMS.0074 – Definitions and Acronyms:4.1 - ABNT: Brazilian Association of Technical Standards.4.2 - Rated Area: Any area with a potential risk of explosion.4.3 - Calibration: Set of operations establishing the relationship between the values indicated bya measuring instrument and the values established by the magnitude in the standards.4.4 - Reliability: Refers to the situation where the equipment remains operational throughout thedesign service life without detectable failure, provided that submitted to compliancemaintenance following the guidelines prescribed in the operating instructions andmanufacturers manuals and not having been overloaded beyond the design limits.4.5 - END – Non-Destructive Testing (NDT): Tests performed with finished or semi-finishedmaterials in order to detect the presence or absence of discontinuities or defects by applying thephysical principles set forth in the procedures, without changing physical, chemical, mechanicalor dimensional characteristics and without interfering with subsequent use thereof.4.6 - EPS - Welding Procedure Specification.4.7 - Hidden Failure: A latent system failure that is manifested when the function is required. Forthe sake of prevention, proactive actions should be in place (procedures).4.8 - Frequency: Number of times an event (impact, oscillation, contact) may occur over a givenperiod of time.
  4. 4. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 4 of 174.9 - HP - Hold Point: Inspection event, reported by the Contractor, which requires analysis,verification or attestation by OGX inspection and without which the inspection process cannotcontinue and be validated.4.10 - Inspection: Set of coordinated activities designed to implement and document the statusof the equipment, piping, sensors, measuring instruments or system.4.11 - Integrity: Property of equipment, piping, sensors, measuring instruments or system,whether damaged or not, to remain operational offering an acceptable risk to safety and toprocess reliability.4.12 - Corrective Maintenance: Maintenance that includes all actions to return a failed system tooperational status or available.4.13 - Predictive Maintenance: Maintenance based on the systematic application of analysistechniques, employing centralized monitoring or sampling means in order to optimize Preventiveand Corrective Maintenance.4.14 - Preventive Maintenance: Maintenance aimed to keep the system in operational status oravailable by preventing the occurrence of failures. Maintenance intervals are to be defined inthe Maintenance Plan.4.15 - Monitoring: Component intrinsic design function or performed by security interface whichguarantees the functionality of a security system when a component or a device has its functionreduced or limited, or when there is a hazard due to changes in process conditions.4.16 - NBR: Brazilian Standard.4.17 - NR: Guiding Rule (Labor and Employment Ministry).4.18 - PDCA: Plan (prior to any process, activities must be planned and objectives and methodof execution must be set up), Develop (plan implementation by guiding/coaching people andcollecting data for control), Check (monitoring and evaluation of the process by employingassessment tools and recording, correcting deviations) and Act (determination of a solution forany deviations found thereby improving the process).4.19 - PIT - Inspection and Test Plan: A document prepared by the Operator or the Contractorclearly describing the steps to be taken for implementing the inspections and testings based ona standard, code, requirements, specification, or procedure. The document must indicatechecks and inspections, HP or WP.4.20 - Procedure: Written description of all essential parameters and precautions to be followedfor a given activity, according to the criteria established in a standard, code or specification.4.21 - Skilled Professional: A skilled worker that can demonstrate their skills and abilitiesthrough the application of written comprehensive examinations and documented results that willallow an individual to engage in a specific activity.4.22 - Reference Book: A set of documents systematically organized so as to provide anupdated memory (history) concerning a particular piece of equipment/facility.4.23 - SNQC - National System of Qualification and Certification of Personnel.4.24 - WP - Witness Point: Inspection event, reported by the Contractor, where Contractornotifies OGX inspection aiming the analysis, verification or attestation of the events previouslyassigned in the Inspection and Test Plan (PIT), without discontinuing the manufacturingprocess.4.25 - Qualified Professional: A worker holding legal authority to exercise engineering activitiesin design, monitoring of operation, maintenance, inspection and supervision of boilers andpressure vessels in accordance with professional regulations in force.
  5. 5. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 5 of 175 – Responsibilities:5.1 - Top Management: must ensure compliance with the conditions specified in this procedure.5.2 - Unit Management: Ensure the implementation of this procedure in the operational areasunder their responsibility.5.3 - SMS Management: Support the operational areas in the implementation of this procedure,as well as conduct periodic audits to check the implementation and any deviations.5.4 - Maintenance Management: Perform all activities in compliance with the guidelines in thisprocedure.5.5 – Contractor: Operate and carry out this management practice.6 – Assumptions:6.1 – Planning6.1.1 – ProceduresImplementation, inspection and testing procedures (operating procedures) must be prepared soas clearly to set out the actions to be performed. The system must ensure continuous controland updating (PDCA cycle).The requirements of any procedures issued by contractors must be perfectly aligned with OGXsSGSO guidelines.Check lists – to validate the evidences that actions have been performed and attested.Procedures must communicate the minimum qualifications of the personnel involved in testsand inspections and in the development of specific procedures. E.g.: END and WeldingInspectors must be SNQC-certified. EPS qualification and END procedures, Inspectors atrequired level.6.1.2 – PlansPITs (Inspection and Test Plans) and Maintenance Plans must clearly communicate whichpieces of equipment belong to the Critical Operational Safety System. The contents of the PITmust be aligned with Annex 3.The following must be considered in the objective of the Inspection Plans:• Verification of operation and process compliance with project acceptable variables.• The inspection plan must cover potential damage mechanisms.• Provide information about safety conditions required in the activities (work permit,interlock, radiation protection, confined space, working at height, PPE/CPE, etc.).• Inspection methods must be reliable aiming at: Detection of damage mechanisms; Inaccessible areas must be communicated and, where possible, complementarymethods/ENDs must be employed; Frequency of inspections/tests; Definition of performance acceptability criteria;
  6. 6. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 6 of 17 Progress tracking with results attested by qualified personnel.• Data and results obtained through inspections will be systematically recorded in order toenable: Follow-up in subsequent inspections; Guidelines for planning new inspections; Orientation for any investigations designed to detect and eliminate the causes ofdamage Curbing the progression of the damage; Becoming part of the record keeping system with the history of the equipment –Reference Book.• Results will be analyzed according to the criteria established in the procedures, allowing: Checking/monitoring of equipment current integrity status; Determining equipment remaining life (life cycle); Checking serviceability by comparing the results against the records made for othersimilar pieces of equipment (if possible); Issuing reports with recommendations for better planning/implementation aimingfuture inspection.• The inspection plan must generate maintenance recommendations in order to: Provide feedback for future inspection plans; Monitor implementation thereof and the service time; During plan implementation activities must be inspected and approved by the personin charge of the maintenance or his/her agent.Note: Inspections and tests performed on pressure vessels and boilers framed in NR-13 mustmeet the requirements of this standard and be approved by a qualified professional.6.1.3 – Asset Integrity - Equipment List:Lists must be compiled for better control:• List of equipment and systems belonging to the inspections and tests plan;• List of critical process equipment based on safety and manufacturers information,updated and available to maintenance personnel. Example of critical equipment: pressure vessels and storage tanks; control and pressure relief systems; controls / interlocks / alarms / critical tools; emergency devices, including shutdown systems; emergency response equipment; ventilation systems and devices; piping and fittings in critical service; metering/monitoring devices; emergency communication / alarm systems;
  7. 7. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 7 of 17 key links between process and service; lifting equipment (slings, lugs, baskets, skids, shackles, cranes, etc.). grounding and electrical connections; process pumps/vents/exhausts; emergency generators; other specific critical drilling and vessels equipment.Notes:1 - Any physical identification on the equipment (plate, label, punching, etc.) must be incompliance with the Equipment List/Inspection, Testing and Maintenance Plan) for fieldverification, ensuring perfect correlation (traceability) in the system.2 – The list of facility pieces of equipment must be aligned with the information included in theDescription of the Maritime Unit (DUM) or Description of Onshore Unit (DUT).6.2 – SGSO Quality Assurance Requirements:SGSO requirements must be aligned with OGX SMS Management Manual such as:• Management Commitment;• Policies and Objectives;• SMS Planning;• Review;• Internal Communication;• Audits;• Provision of Resources;• Relations with Suppliers and Contractors;• Metering and Monitoring;• Continuous Improvement.6.3 – Rated Areas:Any equipment belonging to rated areas must be clearly identified in the Equipment List.Consider the highest risk level (zone) according to the restrictions adopted in the standard.Operation (construction and installation) thereof must be made in such a way as to prevent therisk of ignition from sparks (static electricity or friction between moving or hot parts and otherspark sources).It is valuable to have a specific training program in place for electrical equipment in potentiallyexplosive atmospheres to inform the personnel about the risks and the basic security concepts.6.4 – Critical Systems:Critical systems such as controllers, SDCD’s, emergency lighting, protections andinstrumentation, must operate properly even if a failure in normal power feeding system occurs,in order to avoid situations that will worsen facility emergency shutdowns. Contingency actions,
  8. 8. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 8 of 17where possible, must be implemented and described in the operational documents to guaranteethe required reliability.It is relevant to consider such data as: manufacturers’ recommendations, good engineeringpractices, risk analysis study, previous operation experiences and similarity ofequipment/systems.Any critical equipment must have a reference book clearly demonstrating the history ofinterventions. Such book must include, at least, the following information:• A copy of the operating manual supplied by the manufacturer, in Portuguese;• Technical specifications;• Inspection, maintenance and certification program;• Record of inspections, maintenance and certification;• Action plan for correction of non-conformities detected during inspections, maintenanceand certification;• Identification and signature of the technician appointed by the company.Inspection Reports must provide at least the following information:• Items inspected and non-conformities detected, describing those preventing theequipment from being operated and those not interfering with operation;• Corrective action taken for deterrent non-conformities;• Identification of Procedure and reference standard;• Metering devices employed;• Identification of the Unit, equipment and system;• Identification of inspector and inspection report;• Review and approval by SGSOs person responsible;• Numerical identification.A correction schedule must be set up to address those non-conformities not preventing theoperation of the equipment and not posing any danger to health and safety, either alone or incombination.6.5 – Mechanical integrity review meetings:The department is expected to convene periodic meetings to review SGSO mechanical integritywith management, aiming to assess:• Action Plan;• Internal and external audits;• Indicators employed and overall performance;• Effectiveness of corrective and preventive actions;• Assessment/reassessment of risk identification;• Documents review (Procedure and records);• SSO objectives applicable to mechanical integrity;
  9. 9. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 9 of 17• Effectiveness of inspection, testing and maintenance processes;• Appraisal of resources applicable to mechanical integrity (material and personnel);• Analysis of requirements and other requirements applicable to mechanical integrity.6.6 – Bibliographical References ABNT NBR 14725:2009 – Chemicals; ABNT NBR ISO 10004:2004 – Solid Wastes; NR 10 –Electricity Installations and Services; NR 13 – Boilers and Pressure Vessels; ABNT NBR 14842:2003 – Criteria for Welding Inspectors; ABNT NBR ISO 9712:2004 – END, Personnel Qualification;6.7 – Records:See Check lists in Annex 1.7 – Adequacy for the BusinessNot applicable.8 – Annexes:Annex 1 – Check List.Annex 2 - Equipment Integrity Flowchart.Annex 3 - Structure for an Inspection and Testing Plan.Annex 4 - SGSO Document Structure Model.Annex 5 - Diagram proposed for the cause and effect analysis of failures in operating systemcritical equipment.Annex 6 - Functional diagram for analyzing system breakdown.
  10. 10. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 10 of 17Annex 1 – Check ListSGSO – Check List (LV)Nº:REV:MECHANICAL INTEGRITY Page 1/2REFERENCE DOCUMENTANP, SGSO-MN-02-REV.1 - MANUAL PARA EXECUÇÃO DEAUDITORIAS DE VERIFICAÇÃO DA CONFORMIDADE DE SGSO(SGSO CONFORMITY CHECKING AUDIT MANUAL.FACILITY/LOCATION/DATESUPPLIER/PERSON IN CHARGE:INSPECTION/PERSON INCHARGE:CHECKING ITEMS REPORT1 IS THERE ANY EQUIPMENT PREVENTIVE MAINTENANCE SCHEDULE IN PLACE?2 EMPLOYEE AND CONTRACTORS ACCESS TO RISK AREAS IS CONTROLLED AND FLAGGED?3 IS THERE ANY BOILERS AND VESSEL INSPECTION PROGRAM AS PER NR-13?4IS THE NR-13 PROGRAM CONSISTENT WITH THE COMPLEXITY OF THE RISK OF EQUIPMENTAND FACILITIES?5HAVE BOILERS AND PRESSURE VESSELS OPERATORS BEEN GIVEN ADEQUATE TRAININGAS PROVIDED FOR UNDER NR-13.6IS THERE ANY INSPECTION AND LOAD TESTING PROGRAM IN PLACE FOR LIFTINGEQUIPMENT? IS THERE ANY VISIBLE IDENTIFICATION PLATE (LABEL) COMMUNICATING THESTATUS OF LOAD TESTS?7LIFTING EQUIPMENT OPERATORS AND CARRIERS HAVE BEEN GIVEN APPROPRIATETRAINING?8HAVE THE EQUIPMENT INSTALLED IN RATED AREAS BEEN IDENTIFIED IN THE INSPECTIONPROGRAM?9IS THERE APPROPRIATE EQUIPMENT LOCK-OUT/TAG-OUT ROUTINE IN PLACE DURINGMAINTENANCE AND INSPECTION SHUTDOWNS?10 IS THERE A ROUTINE FOR EQUIPMENT SAFE OPERATION IN PLACE?11DOES CRITICAL EQUIPMENT HAVE A HISTORY OF MAINTENANCE, INSPECTION ANDTESTING (REFERENCE BOOK) AVAILABLE?12DOES THE ORGANIZATION SET UP AND KEEP PROCEDURES FOR WORKPLACE DESIGN,PROCESSES, MACHINES OPERATING PROCEDURES AND INSTRUCTIONS, IN ORDER TOELIMINATE OR REDUCE HEALTH AND SAFETY RISK AT THE SOURCE?13 IS THERE SPECIFIC PROCEDURE FOR WORK IN PRESSURIZED PIPELINES IN PLACE?14IS THERE SPECIFIC PROCEDURE FOR APR/PT PREPARATION/ISSUANCE IN PLACE? HAVEAPR/PT BEEN APPROPRIATELY ARCHIVED?15ARE SGSO RELATED RECORDS (REPORTS, CHECK LISTS, CERTIFICATES, ETC.) LEGIBLE,IDENTIFIABLE, TRACEABLE AND WERE PROPERLY STORED?16 IS THERE ANY PROCEDURE IN LACE TO DETECT NEEDED TRAINING?SGSO – Check List (LV)Nº:REV:MECHANICAL INTEGRITY Page 1/2
  11. 11. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 11 of 17REFERENCE DOCUMENTANP, SGSO-MN-02-REV.1 - MANUAL PARA EXECUÇÃO DEAUDITORIAS DE VERIFICAÇÃO DA CONFORMIDADE DE SGSO(SGSO CONFORMITY CHECKING AUDIT MANUAL.FACILITY/LOCATION/DATESUPPLIER/PERSON IN CHARGE:INSPECTION/PERSON INCHARGE:CHECKING ITEMS REPORT1 IS THERE ANY EQUIPMENT PREVENTIVE MAINTENANCE SCHEDULE IN PLACE?2 EMPLOYEE AND CONTRACTORS ACCESS TO RISK AREAS IS CONTROLLED AND FLAGGED?3 IS THERE ANY BOILERS AND VESSEL INSPECTION PROGRAM AS PER NR-13?4IS THE NR-13 PROGRAM CONSISTENT WITH THE COMPLEXITY OF THE RISK OF EQUIPMENTAND FACILITIES?5HAVE BOILERS AND PRESSURE VESSELS OPERATORS BEEN GIVEN ADEQUATE TRAININGAS PROVIDED FOR UNDER NR-13.6IS THERE ANY INSPECTION AND LOAD TESTING PROGRAM IN PLACE FOR LIFTINGEQUIPMENT? IS THERE ANY VISIBLE IDENTIFICATION PLATE (LABEL) COMMUNICATING THESTATUS OF LOAD TESTS?7LIFTING EQUIPMENT OPERATORS AND CARRIERS HAVE BEEN GIVEN APPROPRIATETRAINING?8HAVE THE EQUIPMENT INSTALLED IN RATED AREAS BEEN IDENTIFIED IN THE INSPECTIONPROGRAM?9IS THERE APPROPRIATE EQUIPMENT LOCK-OUT/TAG-OUT ROUTINE IN PLACE DURINGMAINTENANCE AND INSPECTION SHUTDOWNS?10 IS THERE A ROUTINE FOR EQUIPMENT SAFE OPERATION IN PLACE?11DOES CRITICAL EQUIPMENT HAVE A HISTORY OF MAINTENANCE, INSPECTION ANDTESTING (REFERENCE BOOK) AVAILABLE?12DOES THE ORGANIZATION SET UP AND KEEP PROCEDURES FOR WORKPLACE DESIGN,PROCESSES, MACHINES OPERATING PROCEDURES AND INSTRUCTIONS, IN ORDER TOELIMINATE OR REDUCE HEALTH AND SAFETY RISK AT THE SOURCE?13 IS THERE SPECIFIC PROCEDURE FOR WORK IN PRESSURIZED PIPELINES IN PLACE?14IS THERE SPECIFIC PROCEDURE FOR APR/PT PREPARATION/ISSUANCE IN PLACE? HAVEAPR/PT BEEN APPROPRIATELY ARCHIVED?15ARE SGSO RELATED RECORDS (REPORTS, CHECK LISTS, CERTIFICATES, ETC.) LEGIBLE,IDENTIFIABLE, TRACEABLE AND WERE PROPERLY STORED?16 IS THERE ANY PROCEDURE IN LACE TO DETECT NEEDED TRAINING?
  12. 12. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 12 of 17NOTE: REFER TO ANP MANUAL CHECKLIST (REFERENCE DOCUMENT), MANAGEMENT PRACTICENo. 1, FOR THE INCLUSION OF OTHER VERIFICATION ITEMS.APPRAISAL REPORT/CAPTION: S - SATISFACTORY N - NOT SATISFACTORY NA - NOTAPPLICABLENOTES:SGSO – Check List (LV)MECHANICAL INTEGRITY Page 2/2CHECKING ITEMS REPORT17IS THE NEED AND EFFECTIVENESS OF TRAINING PROVIDED ASSESSED? IS THERE ANYEVIDENCE OF SUCH ASSESSMENTS AVAILABLE? IS THERE A PROCEDURE FOR THISSYSTEMATIC ASSESSMENT?18DO CONTRACTORS HAVE RISK ASSESSMENT STUDIES IN PLACE FOR CRITICALPROCESSES (HAZOP, FMEA, ETC.)? IS THERE ANY EVIDENCE OF SUCH STUDIESAVAILABLE? HAS THIS STUDY BEEN DONE BY QUALIFIED PERSON?19IS THE DEFINITION OF THE ASPECTS AND IMPACTS APPLICABLE TO CRITICAL SYSTEMSALIGNED WITH LEGAL REQUIREMENTS AND OTHER REQUIREMENTS? IS THERE ANYEVIDENCE OF PERIODIC REVIEW OF SUCH REQUIREMENTS AVAILABLE?20HAVE THE FUNCTIONS, RESPONSIBILITIES AND AUTHORITIES RELATED TO MECHANICALINTEGRITY BEEN SET UP AND FORMALIZED IN A DOCUMENT?21HAS CONTRACTOR APPOINTED A MANAGEMENT REPRESENTATIVE FOR THE SGSO? WASTHERE FORMAL COMMUNICATION?22DOES CONTRACTOR SET UP AND KEEP A PROCEDURE TO ENSURE THAT ALL SGSORELATED INFORMATION WILL BE DISCLOSED TO EMPLOYEES AND STAKEHOLDERS?23 IS THERE ANY SGSO RELATED PERFORMANCE INDICATORS AVAILABLE?24IS THERE A PROCEDURE FOR PURCHASE, INSPECTION, HANDLING, AND PRESERVATIONOF CRITICAL EQUIPMENT IN PLACE? ARE INSPECTIONS RECORDED?25ARE CONTRACTORS PERIODICALLY ASSESSED/REASSESSED AS TO SGSO? IS THERE ANYEVIDENCE OF SUCH ASSESSMENTS/AUDITS AVAILABLE?26HAVE TESTING AND METERING INSTRUMENTS BEEN CALIBRATED? HAS THE INSTRUMENTCALIBRATION PLAN BEEN APPROVED BY THE QC?27IS THERE ANY SYSTEMATIC STATISTICAL EVALUATION FOR EQUIPMENTAVAILABILITY/FITNESS RATE IN PLACE TARGETING MECHANICAL INTEGRITY? IS THEREANY EVIDENCE OF SUCH SYSTEMATIC APPROACHE AVAILABLE?28ARE DETECTED NON-CONFORMITIES GENERATING ACTION PLANS (WHAT? WHO?WHERE? WHEN? WHY? HOW? HOW MUCH?) TO ENABLE THE IMPLEMENTATION OF THEMITIGATING MEASURES RESULTING FROM THE INVESTIGATION/ANALYSIS PROCESS?29IS ANY ANALYSIS PERFORMED TO VERIFY THE EFFECTIVENESS OF THE PREVENTIVEACTIONS TAKEN?30ARE REVIEW MEETINGS CONVENED TO DISCUSS MECHANICAL INTEGRITY? ARE THEMINUTES OF SUCH MEETINGS AVAILABLE FOR QUERY?30ARE REVIEW MEETINGS CONVENED TO DISCUSS MECHANICAL INTEGRITY? ARE THEMINUTES OF SUCH MEETINGS AVAILABLE FOR QUERY?
  13. 13. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 13 of 17Annex 2 - Equipment Integrity Flowchart.EQUIPMENT INTEGRITY FLOWCHART1• DEFINITION OF INTERNAL AND ESTERNAL DAMAGE MECHANISMS ANDEVIDENCE OF CRITICAL SYSTEM IDENTIFICATION2• SGSO PROCEDURE AND INSPECTION AND TESTING PLAN (PIT).3• OPERATING CONDITIONS MONITORING AND CONTROL4• INSPECTION PROCEDURE5• MAINTENANCE AND REPAIR PROCEDURE6• APPLICABLE REGISTRATIONS
  14. 14. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 14 of 17Annex 3 - Structure for an Inspection and Testing PlanSTRUCTURE FOR AN INSPECTION AND TESTING PLANPITGARANTIA DACOMPATIBILIDADE COM ADOCUMENTAÇÃO APLICÁVELINFORMAÇÕESSOBRE OSDISPOSITIVOSEEQUIPAMENTOS APLICÁVEISESPECIFICAROS CRITÉRIOSDEACEITAÇÃODESCRIÇÃOSUMÁRIA DASETAPAS DO TESTEE/OU INSPEÇÃOCOM POSSÍVEISINTERVENÇÕESINDICAÇÃO DAQUALIFICAÇÃODO PESSOALREQUERIDOINFORMAR OTIPO DEDOCUMENTODE REGISTRO
  15. 15. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 15 of 17Annex 4 - SGSO Document Structure ModelSGSO DOCUMENT STRUCTURE MODELPOLÍTICADO SGSOPROCEDIMENTOS DOSISTEMA.PROCEDIMENTOS/INSTRUÇÕESOPERACIONAIS E PLANOS DE INSPEÇÃO,TESTES E MANUTENÇÃO.REGISTROS/EVIDÊNCIAS COMPROBATÓRIAS (RELATÓRIOS,LISTAS DE VERIFICAÇÃO, CERTIFICADOS ETC)
  16. 16. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 16 of 17Annex 5 - Diagram proposed for the cause and effect analysis of failures in operatingsystem critical equipment.DIAGRAM PROPOSED FOR THE CAUSE AND EFFECT ANALYSIS OF FAILURES INOPERATING SYSTEM CRITICAL EQUIPMENT.FALHATESTE/INSPEÇÃOMANUTENÇÃOOPERAÇÃOPESSOALMATERIALCAUSACAUSA CAUSACAUSACAUSACAUSACAUSACAUSACAUSACAUSACAUSACAUSACAUSA
  17. 17. Management Procedure PG.OG.SMS.018 Issued on: 04/May/12Version02Mechanical Integrity Procedure Page 17 of 17Annex 6 - Functional diagram for analyzing system breakdownFUNCTIONAL DIAGRAM FOR ANALYZING SYSTEM BREAKDOWN------------------------------------------------------------------------------------------------------------------------------Note: Example of failure/effects mode analysis in systems/equipment in items/components byemploying splitting levels (review). The purpose is to communicate the operating conditionsrequired for the system.COMPRESSORMOTORINSTRUMENTAÇÃOEMONITORAMENTORESERVATÓRIODE AR ECONEXÕESLUBRIFICAÇÃOREFRIGERAÇÃOVÁLVULAS DEALÍVIO E LEITURADE PRESSÃO ESOBRECARGAVÁLVULA DE ALÍVIOE LEITURA DEPRESSÃO DA ÁGUADE REFRIGERAÇÃO1º NÍVEL DE ANÁLISE2º NÍVEL DE ANÁLISE3rd LEVEL ANALYSIS

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